Instruction Manual XP BOILER 25589 Highway 1 McBee, SC 29101 MODELS: XB/XW 1000, 1300, 1700 2000, 2600, 3400 SERIES 100/101 INSTALLATION - OPERATION MAINTENANCE - LIMITED WARRANTY WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
TABLE OF CONTENTS TABLE OF CONTENTS �������������������������������������������������������������������������� 2 SAFE INSTALLATION, USE AND SERVICE ����������������������������������������� 3 GENERAL SAFETY ������������������������������������������������������������������������������� 4 INTRODUCTION ������������������������������������������������������������������������������������ 5 Model Identification ���������������������������������������������������������������������������� 5 Abbreviations Used ����
SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this boiler is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY GROUNDING INSTRUCTIONS HIGH ALTITUDE INSTALLATIONS This boiler must be grounded in accordance with the National Electrical Code, Canadian Electrical Code and/or local codes. Boiler is polarity sensitive; correct wiring is imperative for proper operation. This boiler must be connected to a grounded metal, permanent wiring system, or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the boiler.
INTRODUCTION QUALIFICATIONS This Instruction Manual covers XP Boiler models XB/XW 1000, 1300, 1700, 2000, 2600, 3400 - Series 100/101. The instructions and illustrations contained in this Instruction manual will provide you with troubleshooting procedures to diagnose and repair common problems and verify proper operation. QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this boiler requires ability equivalent to that of a Qualified Agency, as defined by ANSI below. In the field involved.
DIMENSIONS AND CAPACITY DATA Figure 1. SINGLE HEAT EXCHANGER BOILER Table 1.
Figure 2. DOUBLE HEAT EXCHANGER BOILER Table 3.
RATINGS Table 5. IBR RATINGS MODELS (XB/XW) INPUT MBH GROSS OUTPUT MBH (NOTE 1) NET I=B=R RATINGS WATER MBH (NOTE 2) MAX MIN 1000 920 100 856 744 1300 1300 130 1209 1051 1700 1700 170 1581 1375 2000 2000 100 1860 1617 2600 2600 130 2418 2103 3400 3400 212 3162 2750 Notes: 1. The ratings are based on standard test procedures prescribed by the United States Department of Energy. 2.
FLOW, HEAD AND TEMPERATURE RISE Table 7. XB MODELS - FLOW, HEAD AND TEMPERATURE RISE Models Input (Btu/hr) Output (Btu/hr) XB-1000 920,000 855,600 XB-1300 1,300,000 1,209,000 XB-1700 1,700,000 1,581,000 XB-2000 2,000,000 1,860,000 XB-2600 2,600,000 2,418,000 XB-3400 3,400,000 3,162,000 Temperature Rise - ΔT °F Flow Rate Water Flow 20 30 40 Maximum Minimum GPM LPM ΔP FT ΔP M GPM LPM ΔP FT ΔP M GPM LPM 86 325 26 7.9 120 453 32.5 9.9 156 592 56 211 12 3.7 80 302 15 4.
FEATURES AND COMPONENTS Figure 3.
Figure 4.
COMPONENT DESCRIPTION 19. Heat exchanger access covers Allows access to the combustion side of the heat exchanger coils. 1. Front access door: Provides access to the gas train, burner controllers and the heat exchanger. 20. High gas pressure switch Switch provided to detect excessive supply gas pressure. 2. Air Filter Box: Allows for the connection of the PVC air intake pipe to the boiler through a standard PVC adapter. It uses a filter to prevent dust and debris from entering the boiler. 21.
CONTROL COMPONENTS THE CONTROL SYSTEM The R7910A1138 is a burner control system that provides heat control, flame supervision, circulation pump control, fan control, boiler control sequencing, and electric ignition function. It will also provide status and error reporting. Figure 7. LOW/HIGH GAS PRESSURE SWITCH GAS VALVE The gas valve is a normally closed servo regulated gas valve. The valve opens only when energized by the burner control and closes when the power is removed.
FLAME SENSOR WATER TEMPERATURE SENSORS Each burner is equipped with a flame sensor to detect the presence of the burner flames at high and low fire conditions. If no flame is sensed, the gas valve will close automatically. The voltage sensed by the flame sensor will also be displayed on the Burner Screen. Figure 12. WATER TEMPERATURE SENSORS Temperature sensors are threaded immersion probes. Temperature probes have embedded temperature sensors (thermistors).
BOILER INSTALLATION CONSIDERATIONS GENERAL If the system is of the open type, a pressure reducing valve will not be required as the water supply to the system will be controlled by a manually operated valve. An overhead surge tank is required. A minimum pressure of 15 psi (100 kPa) must be maintained on the boiler at all times to ensure avoidance of potential damage to the boiler which may not be covered by the warranty.
HOT WATER BOILER SYSTEM - GENERAL WATER LINE CONNECTIONS CIRCULATING PUMP A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the boiler. Install in accordance with the current edition of the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1. All bronze circulating pumps are recommended for use with commercial boilers.
In addition, a CSA design-certified and ASME-rated temperature and pressure (T&P) relief valve must be installed on each and every water storage tank in hot water supply system. The T&P relief valve must comply with applicable construction provisions of Standard for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 or CSA 4.4. T&P relief valve must be of automatic reset type and not embody a single-use type fusible plug, cartridge or linkage.
Table 8. SINGLE UNIT INSTALLATION, SUGGESTED GAS PIPE SIZING. MAXIMUM EQUIVALENT PIPE LENGTH (IN FEET). It is important to guard against gas valve fouling from contaminants in the gas ways. Such fouling may cause improper operation, fire or explosion. If copper supply lines are used they must be approved for gas service. When local codes require a main manual shut-off valve outside the boiler jacket, a suitable main manual shut-off valve must be installed in a location complying with those codes.
LOW VOLTAGE CONTROL WIRING • Auto body shops • Plastic manufacturing plants • Furniture refinishing areas and establishments • New building construction • Remodeling areas Common household products, pool and laundry products may contain fluorine or chlorine compounds. When these chemicals come in contact with the boiler, they react and can form strong acids. The acid can spoil the boiler wall, causing serious damage and may result in flue gas spillage or boiler water leakage into the building.
Nominal Iron Pipe Size (Inches) 1 1/2 BTU/hr kW 2 BTU/hr kW 2 1/2 BTU/hr kW 3 BTU/hr kW 4 BTU/hr kW Nominal Iron Pipe Size (Inches) 1 1/2 BTU/hr kW 2 BTU/hr kW 2 1/2 BTU/hr kW 3 BTU/hr kW 4 BTU/hr kW 10 (3.05) 3,276,000 959 6,162,000 1,805 9,828,000 2,878 17,160,000 5,026 35,880,000 10,508 10 (3.05) 2,100,000 615 3,950,000 1,157 6,300,000 1,845 11,000,000 3,222 23,000,000 6,736 20 (6.
GENERAL REQUIREMENTS REQUIRED ABILITY REPLACING EXISTING COMMON VENTED BOILER Installation or service of this boiler requires ability equivalent to that of a licensed tradesman in the field involved. Plumbing, air supply, venting, gas supply, and electrical work are required. NOTE: This section does not describe a method for common venting XP units. It describes what must be done when a unit is removed from a common vent system. The XP units require special vent systems and fans for common vent.
PANELS AND COVERS LEVELING All panels and covers (e.g. control and junction box covers; front, side and rear panels of boiler) must be in place after service and/ or before operation of boiler. This will ensure that all gas ignition components will be protected from water. Because this unit is a Category IV appliance it produces some amounts of condensation. The unit has a condensation disposal system that requires this unit to be level to properly drain.
CONFINED SPACE OUTDOOR AIR THROUGH TWO OPENINGS A confined space is one whose volume is less than 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Openings must be installed to provide fresh air for combustion, ventilation and dilution in confined spaces.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 20. Each duct opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.
VENTING STAINLESS STEEL INSTALLATION: Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL1738 approved system for the United States and a ULC-S636 approved system for Canada. Installation of the approved AL 29-4C stainless steel venting material should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.
AIR INLET PIPE MATERIALS VENT AND AIR PIPE INSTALLATION Make sure the air inlet pipe(s) are sealed. The acceptable air inlet pipe materials are: 1. Measure from the boiler level to vent. Refer to the Table 14 on Page 36 for the allowable lengths. • PVC/CPVC • AL 29-4C An adapter is provided for transition between the air inlet connection on the boiler and the plastic air inlet pipe. 2. Prepare pipes to the required lengths and deburr the inside and outside of the pipe ends.
(30.5 m). A maximum of three 90° elbows can be used. Minimum vertical vent is 7 equivalent feet (2.1 m) for direct vent installations. Standard minimum vertical vent length is 7 feet (2.1 m). See Figure 25, Figure 28 thru Figure 30 for differences between standard and direct vent installations. 3. An AL 29-4C® Vent Vertical Vent Terminal must be used at the termination. 4. Maintain a minimum of 6 feet (2.0 m) separation between the air intake and the exhaust terminals.
MODELS (XB/XW) VENT KIT NUMBERS (RAIN CAP) 1000 320884-000 1300 320884-001 1700 320884-001 2000 320884-001 2600 320884-001 3400 320884-002 Figure 25. VERTICAL VENTING MODELS (XB/XW) VENT KIT NUMBERS (TEE) 1000 321765-000 1300 321765-001 1700 321765-001 2000 321765-001 2600 321765-001 3400 321765-002 Figure 26.
MODELS (XB/XW) VENT KIT NUMBERS (TEE) AIR INTAKE KIT NUMBERS (ELBOW) 1000 321765-000 321764-000 1300 321765-001 321764-000 1700 321765-001 321764-001 2000 321765-001 321764-001 2600 321765-001 321764-001 3400 321765-002 321764-002 Figure 27.
MODELS (XB/XW) VENT KIT NUMBERS (RAIN CAP) AIR INTAKE KIT NUMBERS (ELBOW) 1000 320884-000 321764-000 1300 320884-001 321764-000 1700 320884-001 321764-001 2000 320884-001 321764-001 2600 320884-001 321764-001 3400 320884-002 321764-002 Figure 29.
TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION G V D H A v E L v B FI XE D CLOSED V F OPERABLE V B B C OPERABLE V B B FI XE D CLOSED V M X V K J A X V B V X VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Figure 31. POWER VENT Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION G V D H A v E L v B FI XE D CLOSED V F B B C OPERABLE V OPERABLE V B B FI XE D CLOSED V M X V K J A X V B V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Figure 32. DIRECT VENT Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porch
DIRECT VENT: HORIZONTAL TERMINATION Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet (1.2 m) horizontally. Gas vent extending through an exterior wall must not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.
DIRECT VENTING: VERTICAL TERMINATION Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. VENT/AIR TERMINATION LOCATIONS: Follow these guidelines for locating the vent/air terminations: 1. Make sure the total length of piping for vent or air do not exceed the limits mentioned in Table 14 and Table 15 on Page 36. 2.
Table 13. PVC, VENT PIPE, AND FITTINGS ALL VENT PIPE MATERIALS AND FITTINGS MUST COMPLY WITH THE FOLLOWING: ITEM MATERIAL STANDARDS FOR INSTALLATION IN: UNITED STATES Vent pipe and fittings Pipe cement/primer PVC schedule 40 ANSI/ASTM D1785 CPVC schedule 40/80 ANSI/ASTM F441 PVC ANSI/ASTM D2564 CPVC ANSI/ASTM F493 CANADA CPVC and PVC venting must be ULC-S636 Certified. ULC-S636 Certified. NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE Table 14.
CONDENSATE DISPOSAL CONDENSATE NEUTRALIZER Figure 38. CONDENSATE DISPOSAL SYSTEM Figure 40. CONDENSATE NEUTRALIZER The condensate drains from the boiler have pH levels between 4.3 and 5.0. The pH measurement of a fluid is an indicator of the acidity or alkalinity. Neutral fluids have pH of 7.0. Acid fluids have pH below 7. Some local codes may require the use of a condensate neutralizer to raise the pH level of the condensate leaving the boiler.
GAS SUPPLY CONNECTIONS GAS SUPPLY PIPE CONNECTIONS 6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow. Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. 7. Make sure the maximum inlet gas pressure do not exceed the value specified. Minimum value specified is for input adjustment only.
PIPE SIZES FOR PROPANE GAS Make sure to contact the gas supplier for pipe sizes, tanks, and 100% lockup gas pressure regulator. PURGING GAS LINE Gas line purging is required with new piping or systems in which air has entered. Gas purging should be performed per NFPA 54 for US and CAN B149.1 for Canada. CHECK GAS SUPPLY INLET PRESSURE CSA or UL listed flexible gas connections are acceptable, but make sure that the line has adequate capacity to allow your boiler to fire at full rate.
BOILER START UP AND OPERATIONS IMPORTANT Only an A.O. Smith Certified Start-up agent must perform the initial firing of the boiler. At this time the user should not hesitate to ask the start-up agent any questions regarding the operation and maintenance of the unit. If you still have questions, please contact the factory or your local A.O. Smith representative. Contact Technical Support noted on the back cover for the name of your closest Certified Start-Up agent.
Table 18. WATER HARDNESS MEDIUM (0-12 GRAINS PER GALLON) HOT WATER CAN SCALD: Boilers are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm or physically/mentally disabled.
LIGHTING AND OPERATING INSTRUCTIONS 42
ADJUSTMENT There must be sufficient load to operate the boiler at high fire to perform the following adjustments. Start the boiler and observe proper operating parameters for the system. Figure 44. BURNER INFORMATION SCREEN Required Tools: Click on Operation button, and under the Modulation Menu, set the required Firing rate (High/Low) by setting the RPM.
HIGH FIRING RATE SETTING Set the boiler to the high firing rate by setting the High Firing Rate RPM as described below. Check combustion readings using a combustion analyzer. If combustion readings are not in accordance with the chart below adjust the gas valve as follows: remove the flat, round, blue plastic cap from the cover. Using a 3 mm (7/64”) hex wrench, turn the adjustment screw counterclockwise to increase or clockwise to decrease gas flow and achieve the desired CO2 level.
CONTROL SYSTEM 3. Three Pump Outputs with 5 selectable operation modes. BURNER CONTROL SYSTEM 4. 24VAC: • Output control of gas valve (Pilot and Main) and External Ignition Transformer. • Digital inputs for room limit control, high limit control, Gas pressure switch, low water cutoff. 5. External spark transformer. 6. Flame Sensor. 7. Test jacks for flame signal measurement from either a flame rod or UV flame sensor. 8. Alarm Output. Figure 47.
COMMUNICATIONS AND DISPLAYS CSD-1 Acceptable. Meets CSD-1 section CF-300 requirements as a Primary Safety Control. Meets CSD-1 section CW-400 requirements as a Temperature Operation control. Meets CSD-1 section CW-400 requirements as a Temperature High Limit Control when configured for use with 10 kohm NTC sensors. Federal Communications Commission, Part 15, Class B. Emissions. Two modes of communications are available to the R7910. 1. 2.
6. MAIN FLAME ESTABLISHING PERIOD (MFEP): GENERAL OPERATIONAL SEQUENCE a. Lockout Interlock opens (if enabled). b. Pilot valve terminal is not energized. c. Main valve terminal is not energized. d. No flame present at the end of MFEP. e. Internal system fault occurred. INITIATE 7. RUN PERIOD: • Frequency fluctuations vary +/-5% (57 to 63 Hz). • If Demand, LCI, or Stat interrupt (open) during the Prepurge Period. • After the reset button is pressed or fault is cleared at the displays.
DOMESTIC HOT WATER LEAD LAG (LL) MASTER GENERAL OPERATION Start-up sequence DHW-request (system in standby): The XP Boiler is a multiple burner application and it works on the basis of the Lead Lag Operation. The XB Boiler is factory configured for Hydronic/Central Heating application, whereas the XW Boiler is factory configured for Domestic Hot Water application. The LL master coordinates the firing of its slave Control Systems.
LOCAL OPERATOR INTERFACE: DISPLAY SYSTEM For example: — If its add-stage action has been triggered, it will remain in this condition until either a stage has been added, Or — The criteria for its being in an add-stage condition is no longer met; only then will it take another look around to see what state it should go to next. DEFINITIONS Modulating stage: The modulating stage is the Control System that is receiving varying firing rate requests to track the load.
• • • • • • • • • • • • • Allows for lead/lag commissioning. Locates attached boiler(s). Allows boiler naming. Color 3.5 in. x 4.625 in. (5.7 in. diagonal) user interface display. Graphic user interface. Touch screen. Communication between the OI Displays and the Burner Control Systems uses Modbus™. Flush mounting. Touch screen disable for screen cleaning. 12 VDC power supply (included). Screen saver. Contrast control. Volume control. 10. Drill 1/4 in.
STARTING UP THE S7999B OI DISPLAY On System applications, each Burner Control System is represented on the Home page by an icon and name. Pressing the icon allows the user to zoom in on that boiler and see its specific details. These details are provided on a new page, which can include additional buttons that display additional detail and operation information, which itself leads to other pages. The pages are traversed in a tree structure method, as shown in Figure 53 on Page 52.
Figure 53.
STATUS OR HOME PAGE CONFIGURE BUTTON A status (summary) page (Figure 54) is displayed when the S7999B display is connected. This status page appears on the S7999B when the Burner control icon is pressed on the “Home” page. The status page displays the current condition of the burner control and displays some of the more important configuration settings. Pressing the Configure button (bottom left) on the Status page opens the Configuration page.
CONFIGURATION PASSWORD KEYBOARD Some parameters require a valid configuration password be entered by the user before the parameter can be changed. The password need only be entered once while the user remains on the configuration pages. Leaving the configuration pages ends the scope of the password. Some pages request user entry of characters. When this type of input is required, a keyboard page appears, as shown in Figure 58.
Note: When the installer proceeds with the safety parameter configuration, the control unlocks the safety parameters in this group and marks them unusable. Failure to complete the entire safety configuration procedure leaves the control in an unrunnable state (lockout 2). All safety configuration parameters in the group should have the same access level. If this condition isn’t so, the user is asked to enter another password when a higher access level is needed.
FAULT/ALARM HANDLING Each Burner Control reports to the OI display when a safety lockout or an Alert occurs. Safety lockouts are indicated on each configuration page as an alarm bell symbol. At the status page (for S7999B), the History button turns red. If the S7999B is displaying the system status icons, the control in alarm will turn red. The lockout history can be displayed by pressing on the History button.
This History dialog box provides an exploded view of the status information displayed in the History button (the font is larger). One of the four buttons (OK, Lockouts, Alerts, or Silence) can be selected. If none of these buttons are selected the dialog box closes after 30 seconds. Note: The system time can be set in the OI display to ensure that correct timestamps are given to the controls’ lockouts and alerts.
Figure 68. CONTROL EXPANDED ALERT DETAIL Figure 70. PROGRAMMABLE ANNUNCIATION OPERATION BUTTON The operation button displays the Burner Control running operation, including setpoint and firing rate values. From this page the user can change setpoints, manually control the boiler’s firing rate, manually turn pumps on, view annunciation information, and switch between hydronic heating loops (Central Heat and Domestic Hot Water), as shown in Figure 69.
DIAGNOSTICS BUTTON SYSTEM CONFIGURATION (S7999B OI DISPLAY ONLY) The Diagnostics button displays analog and digital I/O status of the Burner Control. A snapshot of the diagnostic status is displayed and updated once per second as it changes in the control. The OI Display has some functions related to general configuration for the control in the end user installation. Pressing the Display Refresh button invokes a search procedure (see Figure 74).
SYSTEM SYNCHRONIZATION (S7999B OI DISPLAY ONLY) CONFIGURATION The user can manually synchronize configuration data from the connected controls at any time. The Burner Control can be configured from the OI Display. The control configuration is grouped into the functional groups as shown in Table 23. Table 23. FUNCTIONAL CONFIGURATION GROUPS A new control is visible when configuration and status data is gathered from it. This collection procedure takes a few minutes.
TROUBLESHOOTING To support the recommended Troubleshooting, the R7910 has an Alert File. Review the Alert history for possible trends that may have been occurring prior to the actual Lockout. Note Column: H= Hold message; L=Lockout message; H or L= either Hold or Lockout depending on Parameter Configuration. Table 24. TROUBLESHOOTING CODES CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE Safety Data Faults 1 Unconfigured safety data 1. 2. 2 Waiting for safety data verification 1.
CODE DESCRIPTION 30 Internal fault: Flame bias shorted to adjacent pin 31 Internal fault: SLO electronics unknown error 32 - 46 Internal fault: Safety Key 0 through 14 RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES Internal Fault. 1. Reset Module. 2. If fault repeats, replace module. NOTE H H L System Errors 47 Flame Rod to ground leakage H 48 Static flame (not flickering) H 49 24 VAC voltage low/high 1. 2.
CODE DESCRIPTION 67 ILK OFF 68 ILK ON RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES 1. 2. 3. 4. NOTE Check wiring and correct any possible shorts. Check Interlock (ILK) switches to assure proper function. Verify voltage through the interlock string to the interlock input with a voltmeter. If steps 1-3 are correct and the fault persists, replace the module. H or L H or L 69 Pilot test hold 1. 2. 3. Verify Run/Test is changed to Run. Reset Module. If fault repeats, replace module.
CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 94 Header sensor fault 1. 2. 3. Check wiring and correct any possible errors. Replace the header sensor. If previous steps are correct and fault persists, replace the module. H 95 Stack sensor fault 1. 2. 3. Check wiring and correct any possible errors. Replace the stack sensor. If previous steps are correct and fault persists, replace the module. H 96 Outdoor sensor fault 1. 2. 3.
CODE DESCRIPTION 124 High fire switch OFF 125 High fire switch stuck ON RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES 1. 2. 3. 4. 126 Low fire switch OFF 127 Low fire switch stuck ON 1. 2. 3. 4. 128 Fan speed failed during prepurge 129 Fan speed failed during preignition 130 Fan speed failed during ignition 131 Fan movement detected during standby 132 Fan speed failed during run 133-135 RESERVED 1. 2. 3. 4. Check wiring and correct any potential wiring errors.
CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 150 Flame not detected OEM Specific 1. Sequence returns to standby and restarts sequence at the beginning of Purge after the HF switch opens. If flame detected during Safe Start check up to Flame Establishing period. H 151 High fire switch ON OEM Specific 1. Check wiring and correct any potential wiring errors. 2. Check High Fire Switch to assure proper function (not welded or jumpered). 3.
CODE DESCRIPTION 164 Block intake ON 165 Block intake OFF 166-171 RESERVED RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE OEM Specific 1. Check wiring and correct any errors. 2. Inspect the Block Intake Switch to make sure it is working correctly. 3. Reset and sequence the module. 4. During Standby and Purge, measure the voltage across the switch. Supply voltage should be present. If not, the Block Intake Switch is defective and needs replacing. 5.
CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES 1.
Table 25.
CODE DESCRIPTION CODE Fan Parameter Errors 74 Periodic Forced Recycle 75 Absolute max fan speed was out of range 76 Absolute min fan speed was out of range 77 Fan gain down was invalid 78 Fan gain up was invalid 79 Fan minimum duty cycle was invalid 80 Fan pulses per revolution was invalid 81 Fan PWM frequency was invalid 82-83 RESERVED 114 Lead Lag CH 4-20 mA water temperature setting 85 No Lead Lag add stage error threshold was configured 86 No Lead Lag add stage detection time w
CODE DESCRIPTION CODE DESCRIPTION 152 Minimum water temperature parameter was greater than time of day setpoint 191 Lead Lag base load common setting was invalid 153 Minimum pressure parameter was greater than setpoint 192 Lead Lag DHW demand switch setting was 193 Lead Lag Mix demand switch setting was invalid 154 Minimum pressure parameter was greater than time of day setpoint 194 Lead Lag modulation sensor setting was invalid 195 155 CH modulation rate source parameter was invalid Le
CODE DESCRIPTION 231 Lead Lag CH setpoint was invalid 232 Lead Lag CH time of day setpoint was invalid 233 LL outdoor temperature was invalid 234 Lead Lag ODR time of day setpoint was invalid 235 Lead Lag ODR time of day setpoint exceeded normal setpoint 236 Lead Lag ODR max outdoor temperature was invalid 237 Lead Lag ODR min outdoor temperature was invalid 238 CODE DESCRIPTION 274 Abnormal Recycle: Demand off during Pilot Flame Establishing Period 275 Abnormal Recycle: LCI off during
CODE DESCRIPTION CODE DESCRIPTION 304 Abnormal Recycle: ILK off during Measured Purge Time 341 Abnormal Recycle: Hardware SLO electronics 305 Abnormal Recycle: ILK off during Drive to Lightoff Rate 342 Abnormal Recycle: Hardware processor clock 343 Abnormal Recycle: Hardware AC phase 306 Abnormal Recycle: ILK off during Pre-Ignition test 344 Abnormal Recycle: Hardware A2D mismatch 307 Abnormal Recycle: ILK off during Pre-Ignition time 345 Abnormal Recycle: Hardware VSNSR A2D 308 Abnor
CODE DESCRIPTION CODE DESCRIPTION 382 Abnormal Recycle: Fan Speed Range High 482 Internal error: Safety key bit 4 was incorrect 383-450 RESERVED 483 Internal error: Safety key bit 5 was incorrect Circulator Errors 484 Internal error: Safety key bit 6 was incorrect 451 Circulator control was invalid 485 Internal error: Safety key bit 7 was incorrect 452 Circulator P-gain was invalid 486 Internal error: Safety key bit 8 was incorrect 453 Circulator I-gain was invalid 487 Internal err
CODE DESCRIPTION CODE DESCRIPTION 527 Mix circulator sensor was invalid 571 Heat exchanger high limit response was invalid 528 Mix flow control was invalid 572 Heat exchanger high limit was exceeded 529 Mix temperature was invalid 573 530 Mix sensor was invalid Heat exchanger high limit wasn't allowed due to stack limit setting 531 Mix PID setpoint was invalid 574 532 STAT may not be a Mix demand source when Remote Stat is enabled Heat exchanger high limit wasn't allowed due to stack
MAINTENANCE PROCEDURES MAINTENANCE SCHEDULES INSPECT BOILER AREA Yearly procedures for Service Technician: 1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids. 2. Verify that air intake area is free of any of the contaminants. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual. • Check for reported problems.
If the preceding burner characteristics are not evident, check for accumulation of lint or other foreign material that restricts or blocks the air openings to the burner or boiler. To check burners: 1. Shut off all gas and electricity to unit. Allow unit to cool. 2. Remove main burners from unit. 3. Check that burner ports are free of foreign matter. 4. Clean burner with vacuum cleaner. Do not distort burner ports. 5. Reinstall burners in unit.
CONDENSATE REMOVAL SYSTEM 1. Turn off the electrical power, and manual gas shut-off. • Allow boiler parts to cool before disassembly. Due to the highly efficient operation of this unit, condensate is formed during operation and must be removed by the condens ate drain systems. Inspect the condensate drains and tubes at least once a month and insure they will allow the free flow of condensate at all times.
HANDLING CERAMIC FIBER MATERIALS Removal of combustion chamber lining: The combustion chamber insulation in this boiler contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).
AIR SEPARATOR MODEL XB-1000 XB-1300 XB-1700 XB-2000 XB-1600 XB-3400 EXPANSION TANK INLET DIA. 2” 2” 2.5” 3” 3” 4” MAKE-UP WATER Figure 78. PRIMARY/SECONDARY PIPING SYSTEM SYSTEM RETURN WATER FLOW SWITCH TEMPERATURE GAGE CHECK VALVE FULL PORT BALL VALVE FINISHED FLOOR SECONDARY BOILER PUMP - OPTIONAL LOOP TEMPERATURE PROBE DRAIN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE PLACES TEES AS CLOSE TOGETHER AS PRACTICAL OUTLET DIA.
MODEL XW-1000 XW-1300 XW-1700 XW-2000 XW-1600 XW-3400 INLET DIA. 2” 2” 2.5” 3” 3” 4” OUTLET DIA. 2” 2” 2.5” 3” 3” 4” DRAIN Figure 79. HOT WATER SUPPLY BOILER WITH VERTICAL TANK ALTERNATE CONNECTION EXPANSION TANK TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE SYSTEM RETURN WATER FLOW SWITCH TEMPERATURE GAGE CHECK VALVE FULL PORT BALL VALVE COLD WATER SUPPLY LEGEND TEMPERATURE & PRESSURE RELIEF VALVE HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2.
LIMITED WARRANTY A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this boiler: 1. If within TEN years after initial installation of the boiler, a heat exchanger or gas burner should prove upon examination by the warrantor to be defective in material or workmanship, the warrantor, at his option will exchange or repair such part or portion. This term is reduced to FIVE years if this boiler is used for water heating purposes other than hydronic space heating. a.
25589 Highway 1, McBee, SC 29101 Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.